If you manage cold chain shipments, you’ve likely felt the pain of dry ice shortages and rising costs. Um ice substitute dry ice pack sheet encapsulates carbon dioxide (Co₂) snow or phase change material (PCM) inside flexible cells, delivering sub zero temperatures without messy residue. Unlike loose pellets, these sheets extend cooling time, are classified as non hazardous and reduce dependence on scarce CO₂ supplies. In a market where dry ice demand has been growing roughly 5 % per year while CO₂ supply grows only around 0.5 %, price spikes of up to 300 % have become common. With more sustainable materials, longer hold times and simplified compliance, pack sheets promise a smarter way to ship frozen goods in 2025.
What exactly is an ice substitute dry ice pack sheet, E como funciona?
How does it compare to PCM gel packs, water ice packs and traditional dry ice?
Why are businesses switching to pack sheets in 2025, and what are the benefits?
What practical steps ensure safe, efficient use of pack sheets?
What new trends and innovations are shaping cold chain cooling in 2025?
What Is an Ice Substitute Dry Ice Pack Sheet?
An ice substitute dry ice pack sheet is a reusable cooling blanket that combines CO₂ snow or engineered PCM in sealed cells to deliver extremely cold temperatures for extended periods. When the sheet is hydrated and frozen, it achieves temperatures between –20 °C and –60 °C and maintains sub zero conditions for 36–72 horas. Because the refrigerant is encapsulated, it produces minimal gaseous CO₂ and no liquid runoff, making it safer to handle and easier to clean up compared with loose dry ice pellets. Each sheet can be reused multiple times: after use, you simply rehydrate, refreeze and deploy again, reducing waste and costs.
How Does It Compare to PCM Gel Packs?
PCM gel packs absorb and release heat at fixed temperatures, tipicamente 2–8 °C or −20 °C, making them ideal for vaccines, biologics and overnight shipments. No entanto, they cannot achieve the ultra cold range needed for frozen desserts, seafood or cell therapy shipments. Por contraste, pack sheets provide much colder temperatures (–20 °C to –60 °C) and hold them for 36–72 hours. Because the sheet wraps the refrigerant, it also reduces CO₂ emissions and frostbite risk during handling. The table below contrasts pack sheets, PCM packs and other refrigerants.
| Método de resfriamento | Typical temperature range | Duração (approx.) | Practical significance |
| Pack sheet (ice substitute) | –20 °C to –60 °C | 36–72 h | Reutilizável; minimal CO₂ release; ideal para alimentos congelados, biologics and mixed loads |
| PCM gel pack | 2–8 °C or –20 °C | 24–96 h | Maintains precise refrigerator or freezer ranges; reusable and non hazardous |
| Gelo seco tradicional | < –70 °C | 24–48 h | Ultra cold; required for cryogenic materials but regulated and single use |
| Water based gel pack | 0 °C to –20 °C | 24–48 h | Inexpensive; melts evenly but shorter duration |
| Rigid eutectic plate | +2 °C a +8 °C | 48–96 h | Reusable rigid plates for stable refrigerator range; used in closed loop systems |
Practical User Tips and Advice
Hydrate and freeze correctly: Most pack sheets must be soaked in water and frozen solid before use. Follow the manufacturer’s instructions and freeze for at least 24 horas.
Pre condition your container: Chill insulated boxes or pallet shippers before loading to reduce thermal shock and slow sublimation.
Strategic layering: Place the pack sheet on top of the payload so cold air sinks through the cargo. Separate pack sheets and PCM packs with bubble wrap or corrugated board to create thermal zones and prevent direct contact.
Fill voids and insulate: Eliminate warm pockets by filling empty spaces with crumpled paper or foam inserts, and cut the sheet to fit snugly.
Provide ventilation: Even though pack sheets release little CO₂, vent the container to prevent pressure build up, especially when combining sheets with pellets.
Seal and label clearly: Secure the container and label it to show CO₂ or PCM content; clear instructions help carriers handle shipments correctly.
Monitorar temperatura: Use data loggers or IoT enabled sensors to track internal conditions and comply with pharmaceutical regulations.
Real world case study: A biotechnology company switched from standard gel packs to reusable PCM containers for 2–8 °C shipments and, after ten deliveries, saw no temperature deviations and a 40 % reduction in overall costs. In another example, a food shipper replaced loose dry ice with pack sheets and better insulation, extending transit time from 36 para 60 horas e reducing CO₂ usage by 20 %.
Why Switch to Pack Sheets in 2025?
Supply Constraints and Cost Volatility
Industry dynamics make dry ice less reliable. Dry ice consumption has been climbing at roughly 5 % por ano, but CO₂ supply grows only about 0.5 % anualmente, creating shortages and volatile pricing. Spot prices can surge até 300 % during supply crunches. Pack sheets reduce reliance on CO₂ by using less carbon dioxide per shipment and combining it with PCM to extend cooling duration. This helps stabilize budgets and reduces the impact of market swings.
Longer Hold Times and Reusability
Traditional dry ice pellets last 12–24 horas, whereas a pack sheet holds sub zero temperatures for 36–72 horas. When combined with high performance insulation, pack sheets can extend hold time por 25 % and cut dry ice consumption by 18 %. Reusable design eliminates frequent replenishment and disposal costs.
Simplified Compliance and Safety
Dry ice is classified as a hazardous material under IATA, DOT and UN regulations; shippers must label, document and train staff accordingly. Pack sheets are non hazardous, so they avoid many regulatory hurdles and simplify customs clearance. Encapsulation reduces frostbite risk during packing, and minimal CO₂ release lowers asphyxiation concerns.
Sustainability and Lower Emissions
Much of the industrial CO₂ used for dry ice is fossil based. Consumers and regulators are demanding greener supply chains. O bioethanol industry captures high purity CO₂ as a fermentation by product, offering a renewable source. In the UK, a single bioethanol plant supplies 30–60 % of the country’s CO₂, illustrating both the potential and vulnerability of this sector. Pack sheets and PCM reduce total CO₂ use, aligning with carbon reduction goals and avoiding landfill waste from single use pellets.
Industry Responses and Hybrids
Facing shortages, dry ice producers are building localized CO₂ recovery hubs and exploring on site capture and reuse. Shippers mix dry ice with PCMs or improve insulation to stretch each pound further. Hybrid strategies—placing a pack sheet underneath frozen goods and PCM above refrigerated items—create separate thermal zones and reduce total CO₂ consumption. These trends show that pack sheets complement rather than completely replace traditional refrigerants, giving operators flexibility.
Selecting the Right Cooling Method
Choosing between pack sheets, PCM, dry ice or a hybrid depends on several factors. The framework below, adapted from industry guidelines and Tempk’s selection criteria, helps you make informed decisions.
Target temperature range:
• 2–8 °C or –20 °C – Use PCM gel packs or eutectic plates.
• –20 °C to –60 °C – Choose pack sheets for frozen desserts, seafood or cell therapy.
• < –70 °C – Reserve traditional dry ice for ultra cold CRISPR materials and cryogenic samples.
Shipping duration:
• 24–96 hours – PCM packs excel for refrigerated ranges.
• 36–72 horas – Pack sheets maintain below zero temperatures and are extendable with insulation.
• > 96 horas – Consider hybrid solutions or active refrigeration.
Regulatory complexity:
• Want to avoid hazardous labels and training? Choose pack sheets or PCM, which are generally non hazardous.
• Comfortable with hazmat rules? Dry ice remains a low cost option for extremely cold shipments.
Budget and sustainability:
• PCM requires higher upfront investment but offers long term savings through reuse and reduced waste.
• Pack sheets provide a balance—more affordable than high end PCM yet reusable and less wasteful than pellets.
• Dry ice is cheap per shipment but incurs recurring costs for each refill and disposal, with greater emissions.
Sector Specific Considerations
Food and meat processing: Efficiency is key. Thin slices and pellets support rapid cooling during processing, while blocks remain suitable for bulk transport. Better insulation and pack sheets stretch hold times and minimize sublimation.
Pharmaceuticals and laboratories: Biologics and vaccines demand strict temperature control. Barrier technologies that slow CO₂ release and real time temperature monitoring are becoming standard. Pack sheets and PCMs are gaining traction for less temperature critical medicines.
Industrial and welding applications: Dry ice blasting depends on a steady pellet supply. Contractors mitigate shortages by locking in long term contracts or investing in local pelletizing equipment. Hybrid solutions can also reduce dependence on pellets.
2025 Inovações e tendências
Market Growth and Investment
The global dry ice market was valued at USD 1.54 bilhão em 2024 and is projected to reach USD 2.73 bilhão por 2032 em um 7.4 % Cagr. Ao mesmo tempo, o phase change materials market stood at USD 610 million in 2024 and is expected to grow at 17 % anualmente between 2025 e 2032, alcançando USD 2.15 bilhão por 2032. Rapid PCM growth indicates increasing adoption of reusable cooling technologies across building, HVAC and cold chain packaging sectors.
Bio Based CO₂ and Circular Supply Chains
Demand for lower carbon dry ice has spurred investment in bioethanol derived CO₂. Fermentation of crops such as corn and sugar beet releases high purity CO₂, which can be captured and purified for industrial use. In the UK, one bioethanol producer accounts for 30–60 % of national CO₂ supply, highlighting both the opportunity and risk of relying on a few suppliers. Geopolitical shifts—such as the removal of tariffs on U.S. bioethanol imports—can threaten domestic production. Companies are therefore exploring on site CO₂ capture and reuse at food plants to secure supply.
Hybrid Cooling and IoT Integration
Hybrid configurations combining pack sheets with PCM or dry ice are gaining popularity. Para cargas mistas (por exemplo, frozen seafood plus refrigerated produce), a pack sheet can be placed under frozen items while PCM sits above to create separate temperature zones. IoT enabled sensors provide real time visibility into payload conditions, alerting shippers to temperature excursions and helping comply with pharmaceutical regulations.
Improved Insulation and Localized Production
ThermoSafe notes that dry ice sublimates at 3–8 % por dia, depending on container design and ambient temperature. Advanced insulation—such as vacuum panels—reduces sublimation and extends hold times. Manufacturers are building localized production hubs for dry ice to reduce transport losses and match regional demand. These facilities often pair dry ice with on site CO₂ capture to create a circular supply loop.
Perguntas frequentes
Q1: What is an ice substitute dry ice pack sheet?
A pack sheet encapsulates CO₂ snow or engineered PCM in flexible cells. It delivers temperatures from –20 °C to –60 °C for 36–72 hours, producing minimal gas and no liquid residue.
Q2: How long does a pack sheet last?
With proper hydration, pre conditioning and insulation, it holds sub zero temperatures for up to 72 horas. Better insulation can extend hold time by about 25 %.
Q3: Is the pack sheet reusable?
Sim. Após o uso, rehydrate, refreeze and reuse. Reusable design lowers waste and long term costs.
Q4: Can I combine a pack sheet with PCM gel packs?
Absolutamente. In mixed shipments, place the pack sheet below frozen items and PCM above refrigerated goods to create separate thermal zones.
Q5: Are there regulations for shipping with a pack sheet?
Pack sheets are generally non hazardous, so they avoid many IATA/DOT labeling requirements. Always check specific carrier policies and label your package clearly for safe handling.
Q6: What is the environmental impact compared with dry ice?
Pack sheets use less CO₂ and can be reused, reducing emissions and waste. Traditional dry ice is fossil derived and single use, contributing to higher carbon footprints.
Resumo e recomendações
Takeaways -chave
Supply mismatch: Dry ice demand is growing 5 % annually while CO₂ supply increases just 0.5 %, causing shortages and price spikes.
Pack sheet advantages: Reusable sheets deliver –20 °C to –60 °C for 36–72 hours, minimize CO₂ release and simplify compliance. They extend hold time by 25 % and cut CO₂ usage by 18 % when combined with insulation.
Hybrid flexibility: Combining pack sheets with PCM or dry ice creates thermal zones for mixed loads and reduces overall CO₂ consumption.
Sustentabilidade: Bio based CO₂ capture, reusable packaging and IoT monitoring support greener cold chains.
Market momentum: Dry ice and PCM markets are both growing, but PCM adoption is accelerating at a 17 % CAGR através 2032.
Actionable Guidance
Evaluate your payload: Identify the required temperature range and shipping duration. Select pack sheets for frozen loads or hybrid shipments requiring multiple zones.
Invest in insulation: High performance containers and pre conditioning significantly reduce sublimation. Combine insulation with pack sheets and PCM for optimal results.
Adopt monitoring: Use IoT data loggers to track temperature in real time, ensuring compliance and product integrity.
Plan for sustainability: Seek suppliers using bio based CO₂ or localized production. Reuse refrigerants whenever possible to reduce waste and emissions.
Eduque sua equipe: Train staff on proper hydration, congelando, layering and labeling to maximize the benefits of pack sheets. Develop SOPs that integrate hybrid cooling strategies.
Sobre Tempk
Tempk is a cold chain packaging innovator focused on reusable insulation, PCM refrigerants and advanced data monitoring. Nós develop products such as ice substitute dry ice pack sheets, PCM gel packs and insulated liners that help shippers maintain precise temperatures while reducing waste. Nosso R&D facility continually tests new materials—including bio based CO₂ and smart sensors—to support sustainable cold chain operations. Partnering with industries from e commerce food delivery to pharmaceuticals, we deliver flexível, validated and compliant solutions that protect your products and the planet.
Chamado à ação: Ready to enhance your cold chain strategy? Entre em contato com nossa equipe for a customized temperature control solution or request a sample of our pack sheets and PCM systems.
